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I'm pretty sure the bumper skin is made of polyurethane. As it is a thermoset plastic, melting isn't an option. I would expect a urethane-based filler would work, given proper surface preparation for good adhesion. That is, if anyone makes a urethane filler.

Have you checked the screen in your reservoir to see if it's clogged? That often happens, blocking fluid flow.

The silicone oil inside the fan coupler is thick, as in 1000 cSt thick. I guess it would be like Elmer's glue. If there's not enough of it, the coupler won't work. The easy test is to start the car cold. The fan should whoosh vigorously for about 30 seconds before quieting down. You should...

I'd check the brake pad wear indicators (squealers) first. But also check the bolts that hold the caliper to the bracket. If one of those bolts is slightly too long, it will rub but only while turning. Look for the scrape mark on the rotor. That will at least tell you how far from the hub to...

You can refill the fan "clutch" with new silicone oil. The oil oozes out over time. If the front is all gooey and covered in dirt, that's definitely your problem. Also, it should blow lots of air for almost 30 seconds after you start the car after it has been sitting for a while. It takes...

I cut my "cooler" so very many years ago... But I didn't know about the Magnefine filters back then, either.

The easiest place to add the filter is behind the bumper not far from where the "cooler" is. The "cooler" is just a loop of pipe. I cut off the u-turn closest to the hood latch to add my filter with a tiny pipe cutter. The right size hose will just push onto the pipe far enough to get a couple...

I've had good results with Mobil 1 ATF. You need a Dexron III-compatible fluid, so as long as it says that on the bottle, you're good. Don't use "PSF" - use ATF. While you're at it, you should inspect the reservoir and probably clean it. Typically, the screen in there gets all clogged up and...

Using the steering wheel lock to keep the wheels from turning should work ok. Or, turn the wheels all the way until they hit the stops. The tie rod nuts shouldn't need lots of torque to break loose. Definitely leave the two rack mounts tight until everything else is off.

After you remove the bolt down at the rack, you'll probably need to spritz it with something like PB Blaster. Also, pry the ears apart a little where the bolt goes through. The splines are probably stuck together quite well. You do need to break loose the upper connection because the steering...

The copper gaskets are crush washers, same sort as used on brake line banjo fittings to seal high-pressure fittings. Toyota made the two into one to make assembly easier. The bolt should come out of the banjo. In your photo above, the bolt you removed with the o-ring should have stayed in the...

Not exactly today... but, I broke the Aisin clutch friction plate after only 50k miles. One friction ring came off as all 8 rivets broke. Boo. I replaced it with the ACT "street" kit. While it was out, my transmission needed help because the output bearing vibrated badly. I have a 1st-gen S3...

Follow-up: After maybe 50 miles of driving with the ACT clutch, I can say I recommend this setup. It's only slightly heavier than stock, but feels like butter. I've not romped on it yet, but I'm sure it'll take it. My only complaint is the release bearing it came with had the wrong clip. My...

From experience, I know that an NA will start just fine with the air flow meter disconnected. However, it will not run. It will stall right after it starts.

Pulled the engine and trans last Monday, which wasn't too bad, once I got the wiring harness unwoven out of the intake. Boy, was that a pain. The failure of my clutch was one friction ring came completely off. I sheared off the 8 rivets holding it on. Everything else was fine, including the...

The correct bolt size is M10-1.25. The bolts may have 12mm heads (flat-to-flat), but the bolt shank diameter is 10mm. The thread pitch is 1.25mm. My stand requires long bolts, 90mm long; yours may differ. McMaster-Carr is a great source for bolts in small quantities.

Good idea, gsxr141.

Thanks, guys. I'll go with the ACT kit. I will be reusing my stock flywheel, as I have no interest in going to a lighter one.

My clutch has gone wonky, and my best guess is that one of the rubber blobs in the friction plate has died and fallen out. About 10 years ago, I had a shop rebuild the engine, and they put in a new clutch at the same time. If I had known that Aisin cheapened out at some point, I would not have...

It's a combination of the 4.3 differential and only 5 gears. You'll get used to it.